Hybrid construction for a luggage case

ABSTRACT

A luggage case ( 10 ) has a molded, relatively hard or rigid back portion affixed to the relatively soft fabric constructed front portion ( 12 ). A connector form ( 25 ) constructed of an extruded, flexible shape extends around the peripheral rim ( 19 ) of the back portion, and has a first free end ( 30 ) which is attached by sewing to a gusset ( 21 ) that extends around the front portion ( 11 ). The connector form ( 25 ) has an upper portion that has one and preferably two channels on an outer portion, one of which contains a stiffening wire ( 36 ). The upper portion is fastened by stitching to the rim ( 19 ) of the back portion. The upper portion includes at least a pair of protruding pockets ( 22 ), which define a gap or channel ( 23 ) there between. A strap ( 39 ) attached to opposite sides of the back portion by triangular-shaped anchors, passes through this gap or channel ( 23 ) and had a lifting handle ( 38 ) attached thereto. A shoulder harness has ends that can be attached to an end of the back portion and to the lifting handle ( 38 ) at a shoulder yolk can be used to carry the luggage case ( 10 ) on one&#39;s back.

This application is a 371 of PCT/US 01/3194 filed on Oct. 10, 2001,which claims benefit of 60/239,862 filed on Oct. 11, 2000.

TECHNICAL FIELD

This invention relates to constructing luggage cases from variousmaterials, and in particular luggage constructions that use moldedplastic parts and fabric parts. More particularly, such luggage casesare assembled using industrial sewing operations. Where a major portionof the outside envelope of the luggage case has large molded portionsand large fabric portions, this type of luggage construction isgenerally called hybrid, referring to the fact that the molded portionis generally made like hard shelled luggage cases, but he the fabricportion has many esthetic and technical similarities to so-called softside luggage cases.

BACKGROUND ART

Generally, hybrid luggage cases conceptually are similar to a type ofmolded bottom wheeled duffle bag popular in the 1960's and 1970's. U.S.Pat. No. 5,588,569 shows this type of construction applied to the nowpopular upright case. Later, Samsonite Corporation popularized a line ofluggage that incorporated hybrid construction techniques. This luggagecase is shown in U.S. Pat. No. D427,434.

DISCLOSURE OF INVENTION BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a front isometric view of one embodiment of the luggage casefully packed.

FIG. 2 is a front isometric view of one embodiment of the luggage caseempty with the top surface unzipped.

FIG. 3 is a front isometric view of one embodiment of the luggage caseempty and closed.

FIG. 4 is a close-up exploded view of the connection form and the topand rear portion 11 s of one embodiment of the luggage case joined bythe form.

FIG. 5 is a section view taken along line 5—5 of FIG. 1 illustrating theconnection form, top portion, and rear portion 11 of one embodiment ofthe luggage case in a joined position.

FIG. 6 is a top isometric view of one embodiment of the flap handle.

FIG. 7 is a profile view taken along line 7—7 of FIG. 6 illustrating thelow profile of one embodiment the flap handle.

FIG. 8 is a section view taken along line 8—8 of FIG. 6 illustratingboth the low profile and the preferred connection means of oneembodiment of the flap handle.

FIG. 9 is a close-up exploded view of the strap anchor 51 and theportions of one embodiment of the luggage case to which it attaches.

FIG. 10 is a section view taken along line 10—10 of FIG. 2 illustratingthe connection means of one embodiment of the strap anchor 51.

FIG. 11 illustrates a user carrying one embodiment of the luggage casein the backpack configuration.

FIG. 12 is a front isometric view of one embodiment of the luggage casewith the backpack carry strap attached.

FIG. 13A is a close-up exploded view of the female clasp connected tothe carry strap and the male clasp connected to the front portion 12 ofone embodiment of the luggage case prior to connecting.

FIG. 13B is atop view of one embodiment of the carry strap.

FIG. 14 is a close-up view of one embodiment of the carry strap andconversion clasp in the backpack configuration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Best Mode for Carrying out the Invention

A luggage case incorporating the features of the present invention isshown in FIG. 1. The luggage case 10 includes a rear portion 11 that isvacuum formed from a sheet of flexible thermoplastic, similar to thatused in a typical hard luggage shell construction, a front portion 12attached to the rear portion 11, the front portion 12 being made of asoft-sided luggage construction of fabric shapes and panels, a carryhandle 13 attached at a central location along one of the sides of theluggage case 10, two strap systems 14 used to compress and stabilize theload inside the case, and an optional back pack carry strap 15 (seeFIGS. 11–14). The rear shell portion of the luggage case 10 has arear-facing surface 16, opposing top and bottom surfaces 17, andopposing side surfaces 18. The edge of the opposing side surfaces andthe opposing top and bottom surfaces forms a perimeter rim 19 to whichis attached the front portion 12 of the luggage case 10. The rearportion 11 of the luggage case 10 can include an extendable handle 20,which fits in a collapsed position in the back surface of the luggagecase 10, and extends from that collapsed position to an extendedposition as desired by the user. In conjunction with the extendablehandle 20, at least a pair of wheels (not shown) can be attached to therear portion 11 adjacent the intersection of the back surface with thebottom surface as is conventional for this upright style of luggage casefor convenience in moving the luggage case 10 along a support surface.

Referring still to FIG. 1, and to FIGS. 2 and 3, the front portion 12 ofthe luggage case 10 includes a gusset or collar 21 forming a rim aroundand extending rearwardly from the front surface of the luggage case 10.The front surface of the front portion 12 of the luggage case 10includes a variety of pockets, and as disclosed herein, includes aseries of three pockets 22 extending horizontally and spaced verticallyfrom one another on the front surface of the front portion 12 of theluggage case 10. The three front pockets 22 form two channels 23 therebetween for receiving the strap systems 14, which are described ingreater detail below. The gusset 21 attached to the front surface of thefront portion 12 of the luggage case 10 defines a perimeter which isattached to the perimeter rim 19 of the rear portion 11 of the luggagecase 10. The perimeter of the gusset 21 is attached to the perimeter rim19 of the rear portion 11 of the luggage case 10 by a connector formdesigned specifically to integrate and connect these two pieces togetherin a strong, convenient and durable manner.

The rear and front portion 12s, when attached together, define an innercavity 24 for receiving articles for packing. The volume of the luggagecase 10 in the rear portion 11 is relatively fixed due to the formedhard-sided structure, while the volume of the front portion 12 isvariable given its soft-sided construction. The strap system 14 assistsin stabilizing the load when the luggage case 10 is not filled tocapacity, as is described in greater detail below. The gusset 21 allowsthe luggage case 10 to expand or contract, by the front surface movingtoward or away from the rear portion 11, depending on the desired load.The attachment of the gusset 21 to the rear portion 11 of the luggagecase 10 facilitates either large or small loads easily, and in furthercombination with the support strap system 14 facilitates in securing anyvariety of sizes of loads in the luggage case 10.

The connector form 25 for attaching the rear portion 11 to the frontportion 12 of the luggage case 10 is shown in FIGS. 4 and 5. Thepreferably flexible connector form 25 is made of plastic or rubber andis formed by an extrusion process for continuous application around theentire perimeter rim 19 of the hard shell as well as the entireperimeter of the soft-sided gusset 21. The connector form 25 attaches tothe front portion 12 preferably by a sewing stitch 26, which connectsthe form, the gusset 21, and a liner 28 together. The connector form 25also attaches to the rear portion 11 and gusset 21 preferably by asewing stitch 27.

The cross-sectional shape of the connector form 25 is best shown inFIGS. 4 and 5, and includes a generally straight, downwardly depending(as oriented in FIGS. 4 and 5) inner wall 29. The bottom end of theinner wall 29 is a free end 30 and the top end of the inner wall 29 isattached integrally to the top wall 31 of the connector form 25. Anouter wall 32 of the connector form 25 attaches integrally at its topend with the top wall 31 of the connector form 25. The outer wall 32includes two distinct inwardly directed channels: a top channel 33 and abottom channel 34. The two channels are separated by an indentationforming an outwardly directed slot 35. The outer wall 32 of theconnector form 25 thus generally has a W-shape in cross-section. Theouter wall 32 does not extend as far downwardly as the inner wall 29,which allows the inner wall 29, to which the liner 28 and gusset 21 areattached by stitch 26, to permit free access to properly place thestitch 27 around the perimeter of the rear portion 11.

An interior space is formed in the connector form 25 by the combinationof the inner, top and outer walls, and is continuous along the length ofthe connector form 25. As mentioned above, the connector form 25facilitates the attachment of the front portion 12 to the rear portion11 of the luggage case 10. This is again best shown in FIGS. 4 and 5.Referring still to FIG. 4, a portion of the gusset 21, zipper, topsurface of the soft-sided portion of the luggage case 10, the liner 28for the rear portion 11 of the luggage case 10, the sidewall definingthe rim 19 of the rear portion 11 of the luggage case 10, as well as astiffening member, such as a tempered steel wire 36, that assists inholding the shape of the rear portion 11 and for strengthening theinterface of all these pieces, are shown in an exploded view. Note thatthe perimeter rim 19 of the rear portion 11 of the luggage case 10 hasan outwardly flaring flange 37 around substantially the entire length ofthe perimeter rim 19. Preferably, this flange 37 is formed by trimmingoff the excess thermoplastic material after vacuum forming the backportion.

When attached together, as shown in FIG. 5, the bottom portion of thegusset 21 and the top portion of the liner 28 are attached to the bottomfree end 30 of the inner wall 29 of the connector form 25. The sewingattachment 26 is performed before the connector form 25 is placed on theperimeter rim of the hard-sided rear portion 11. Once the gusset 21 andthe liner 28 are attached to the bottom end of the inner wall 29, theconnector form 25 is then positioned on the rim of the of the luggagecase 10. In doing this, the perimeter rim 19 of the rear portion 11 isreceived in the recess such that the outward flange 37 at the top of therim 19 of the rear portion 11 is received in the top channel 33. Theinside surface of the inner wall 29 of the connector form 25 engages theinside surface of the rim 19, with the flange 37 in the inside surfaceof the rim 19 in relatively continuous contact with the inside surfaceof the inner wall 29, as shown in FIG. 5.

The stiffening member is positioned under the flange 37 of the perimeterrim and extends continuously around the rim 19. The stiffening member ispositioned in the top recess channel when the connector form 25 isplaced on the rim 19 of the rear portion 11. The wire 36 helps stiffenthe rim 19 structure for stability and durability during use. Theconnector form 25 is then attached to the hard-sided luggage portion andthe gusset 21 by placing a sewing stitch line 27 continuously around therim 19 of the hard-sided portion in the indentation 35 formed on theouter wall 32 of the connector form 25. The sewing extends through theouter wall 32 of the connector form 25, through the wall of the rearportion 11, and finally through the inside wall of the connector form25. Optionally for firmer attachment, this sewing stitch could also passthrough and thus attach the gusset 21 as well. Preferably however, thefabric portions of the front portion 12 are stuffed into the cavity 24of the bottom portion during this final sewing operation, well out ofthe way of the sewing machine arm and guide dogs used to place thestitch line 27. This permits the sewing machine operator to concentrateon manipulating the cumbersome luggage case 10, repositioning it to feedthe assembled connector form 25, stiffening member, and the front andback portions during sewing. The lower channel of the outer wall 32 ofthe connector form 25 is not further attached to the hard-sided rearportion 11.

The use of the connector form 25 to attach the soft-sided front portion12 to the hard-sided rear portion 11 allows for a simple yet strongattachment structure. By not attaching the lower free end 30 of theinner wall 29 of the connector form 25 to the rear portion 11, the linerand the lower portion of the inside wall can flex away from thehard-sided portion as needed, which alleviates stress on that connectionpoint. Attaching the connector form 25 to the hard-sided portion throughall four layers as described above at a location between the top andbottom channels securely positions the top rim 19 of the hard-sidedportion securely in the top channel 33, as well as keeps the wire 36stabilizing member in proper position.

As mentioned above and shown in FIGS. 1–3, in a preferred embodiment ofthe present invention, a carry handle 13 is attached at a centrallocation along one of the sides 17 or 18 of the luggage case 10. In analternative embodiment of the present invention, a low-profile flaphandle 40 replaces the carry handle 13 illustrated in FIGS. 1–3. Asshown in FIGS. 6–8, the flap handle 40 is generally attached inapproximately the same location as the preferred embodiment carry handle13. The flap handle 40 serves the same function as the carry handle withthe additional feature of being low-profile with respect to the sidesurface of the luggage case 10 (see FIG. 7).

As shown in FIGS. 6–8, at one end of the flap handle 40 is a baseportion 41 having connection apertures through which connection rivetsare inserted to attach the flap handle 40 to the side of the luggagecase 10. The base portion 41 can run substantially along the width ofthe luggage case 10, if shorter, can be centrally located. A matchingbase cap 42 that also includes connection apertures covers the baseportion 41. A central portion 43 is formed adjacent the base portion 41and includes at least one groove 44 running across the width of the flaphandle 40. The groove 44 serves to form an integral hinge portion. Asemi-circular carry handle portion 45 is formed adjacent the centralportion. The carry handle portion 45 includes a central handle aperture46 bordered along the top by a ribbed handle portion 47. Preferably, thehandle aperture 46 is sized to allow a typical user to grasp the flaphandle 40. In addition, the ribbed handle portion is configured toincrease the comfort and grip of the user. The ribbed handle portion 47also serves to give the user a portion of the handle to grasp whenpulling the handle upward away from the side surface 17 of the luggagecase 10.

In a preferred embodiment, the flap handle 40 is made of a resilient,substantially flexible material. Preferably, the flexible nature of thematerial in conjunction with the groove or grooves will provide anintegral hinged portion that allows the carry handle portion of the flaphandle 40 to be pulled upward, away from the side surface of the luggagecase 10 to act as a carry handle for the luggage case 10.

As mentioned above and illustrated in FIG. 7, when the flap handle 40 isnot being used, it lays substantially flat along the surface of theluggage case 10 thereby creating a low-profile handle with respect tothe surface of the luggage case 10.

In FIG. 8 is a section view illustrating the low profile of the flaphandle 40 and a preferred means of connecting the flap handle 40 to theside 17 of the luggage case 10. The flap handle 40 is connected to theside of the luggage case 10 via fasteners, such as rivets, that areinserted through the connection apertures in the flap handle 40 andthrough the molded shell of the luggage case 10.

As mentioned above and illustrated in FIGS. 1–3, the luggage case 10includes two strap systems in the channels 23 formed between the pockets22 on the front portion 12 of the luggage case 10. Each carry strapsystem 14 includes a central carry handle 38, an adjustable strap 39running through and extending from both sides of the carry handle 38, aconnection clasp 50 including male portions attached to both ends of theadjustable strap 39, and female portions pivotally attached to the endsof generally triangularly shaped wrap-around strap anchors 51. Theadjustable strap 39 is attached to the front surface of the frontportion 12 by rivets, sewing or other means.

As mentioned above, the strap system 14 assists in stabilizing the load,when the luggage case 10 is not filled to capacity. The user may eitherincrease or decrease the length of the strap depending on the size ofthe load. When the luggage case 10 is not filled to capacity, the userwill want to decrease the length of the strap thereby compacting thesoft side front portion 12 into the hard side rear portion 11 of theluggage case 10. In the opposite case, the user will want to increasethe length of the strap to allow the soft side top portion of theluggage case 10 to expand thereby creating more volume to accommodate alarger load.

The support strap system strap anchors 51 are configured to extend fromthe molded rear portion 11 and wrap around a portion of the soft sidefront portion 12. By wrapping around or partially over the soft sidefront portion 12 of the luggage case 10, the strap anchors 51 serve tosupport and protect the soft side portion of the luggage case 10 andprotect the luggage case 10 from side impact forces.

As illustrated in FIG. 9, each strap anchor 51 includes two pieces: afirst piece having a base portion 52, an intermediate hinged portion 54,and a generally triangular, apertured top portion 55; and a secondbottom face plate piece 53 that covers the base portion 52. Both thebottom face plate and the base portion 52 include aligned connectionapertures for receiving a rivet or screw. Both the bottom face plate 53and the base portion 52 are generally rectangular and are substantiallysimilar in shape. Both the bottom face plate 53 and the base portion 52have generally wedge-shaped cross-sections to minimize the overallprofile of the strap anchor 51 when connected to the luggage case 10,and to enhance its strength. A space (FIG. 10) formed between theapertured top portion 55 and the intermediate hinged portion 54 on theinner surface of the strap anchors 51 receives the connector form 25 andallows the anchor to lie flush on the luggage case 10.

The integral hinged portion located intermediate to the strap anchor 51increases the flexibility of the strap anchor 51 thereby allowing thesupport strap system 14 to give-and-take with the shifting of loads. Thepivot point attachment portion at the top of the strap anchor 51provides additional flexibility. One end of the female connection clasp50 is pivotally connected via a small length of webbing to the pivotpoint attachment portion thereby providing the female connection andthus the entire support strap system 14 additional flexibility. It iscontemplated that the attachment mechanisms on the end of the strapscould be reversed, or could be some other mechanism.

As illustrated in FIG. 10, the strap anchors 51 are generally riveted orscrewed to the side of the hard side rear portion 11 of the luggage case10 through the connection apertures.

An optional backpack carry strap 15 is available to enable the user tocarry the luggage case 10 as a backpack. In the backpack configurationas illustrated in FIG. 11, the user can carry the luggage case 10 byslipping the respective side of the carry strap 15 over the left andright shoulders, as appropriate, of the user. FIGS. 11–14 illustrate theuse of the luggage case 10 in the backpack configuration.

The carry strap 15 is an elongated webbing material 61 with clasps 62attached at each end to engage D-loops 63 located on the bottom cornersof the rear portion 11. Centrally located along the strap is a cushionpad 64 that helps comfort the user when using the strap. The cushion pad64 has a curved yoke shape, with a central portion and two extendingarms. The yoke portion is generally formed from an extendable or elasticmaterial such as neoprene. The webbing 61 can be attached to the ends ofthe arms, or could extend continuously through the cushion. The centralportion is generally wider than the extending arms. As shown in FIG.13A, a female clasp 65 is centrally connected to the carry strap 15 anddirectly on the central portion of the cushion. When used in the backpack configuration, the female clasp 65 connects the carry strap 15 tothe male clasp 66 affixed to the front portion 12 of the luggage case 10(see FIG. 3), preferably in the channel formed between the top andmiddle pockets. It can be near the carry handle 38. The ends of thestrap are attached to the D-loops 63 mounted at, near, or adjacent tothe bottom corners of the rear portion 11.

FIG. 13A illustrates the female clasp 65 and male clasp 66 in anunconnected position. In FIG. 13A, a keyhole shaped aperture 67 isclearly shown, and is formed by generally connecting circles, one ofwhich has a smaller radius. A large open area is formed that opens on asmaller open area. A plate having a cylindrical protrusion 68 extendingtherefrom forms the male clasp. A larger diameter, generally disk-shapedcap is centered on end of the protrusion. The cap is small enough to fitthrough the larger opening in the female clasp 65, but is larger thanthe smaller opening in the female clasp. When the female clasp and maleclasp are connected to form a conversion clasp, the cylindricalprotrusion portion of the male clasp is received in the smaller portionof the keyhole-like aperture in the female clasp.

Preferably, the cylindrical protrusion fits in the smaller opening witha snap-fit so the clasps do not disengage from one another.

FIG. 13B illustrates an alternative embodiment of the carry strap 15. InFIG. 13B, the carry strap 15 includes a centrally located, extendable,elastic-like yoke portion. As shown in FIG. 13B, when in an unstretchedposition, the yoke portion of the carry strap 15 is slightly curved. Atthe apex of the curved yoke portion is a female clasp insert. The claspinsert is integral to the yoke portion. In other embodiments, the claspinsert could be a male clasp or any other similarly functioningconnection means. In the embodiment illustrated in FIG. 13B, the femaleclasp insert is similar to the female clasp described above. It includesa clasp aperture 67 that is keyhole-like in shape with a larger circularaperture joined to a smaller circular aperture.

The yoke portion is preferably constructed of materials that areextendable, expandable, and/or elastic-like. In the embodiment in FIG.13B, the yoke portion is constructed of neoprene. In addition, in apreferred embodiment, the yoke portion is perforated. Perforating theyoke portion can increase the flexibility and extendability of the carrystrap 15. In addition, perforations 69 increase the number of edges thatcontact the user thereby increasing the overall grip of the carry strap15 when used either as a shoulder strap or a backpack strap. Also,perforating the yoke portion of the carry strap 15 increases the airflowbetween the strap and the user thereby helping to cool the contact areasbetween the yoke portion and the user.

The elastic-like yoke portion of the carry strap 15 embodimentillustrated in FIG. 13B stretches from an unstretched first position(solid lines) to a stretched second position (dashed lines) whensuspending a loaded luggage case 10, whether used as a shoulder strap ora backpack strap. The elastic-like yoke portion returns to theunstretched first position when not suspending a load. The elasticquality of the yoke material serves as a shock-absorbing device byabsorbing forces generated from the backpack load thereby supporting thebackpack load while maintaining the comfort of the user.

Preferably, whether being used in an over-the-shoulder mode or in abackpack mode, the primary portion of the carry strap 15 to contact theuser is the elastic-like yoke portion. By utilizing the strap in thismanner, the user will receive the most benefit from the comfort featuresdescribed above. Therefore, in a preferred embodiment the overall lengthand adjustability of the carry strap 15 and the length of the yokeportion are sized to ensure that when in use primarily the yoke portionof the carry strap 15 contacts the user, regardless of the user's size.

In other embodiments of the carry strap 15, the yoke portion can beconstructed of a combination of materials exhibiting a combination ofcharacteristics. Some materials may be stretchy or elastic-like and somemay not. Factors to be considered in selection of materials include butare not limited to the cost of materials, the types and weights of loadssupported by the carry strap 15, and the compatibility and ease ofconnecting adjoining materials. For example, in one embodiment, the yokeportion of the carry strap 15 may only include elastic-like materials onthe portions of the yoke that extend over a user's shoulder. The portionof the yoke that remains behind a user's neck may be constructed of anon-elastic material.

FIG. 14 provides a close-up view of the carry strap 15 and conversionclasp illustrated in FIG. 12. In the preferred embodiment shown in FIGS.12 and 14, the male clasp is attached to the top front portion 12 of theluggage case 10 in the space 23 between protruding pockets 22, and thefemale clasp is fixed to the carry strap 15. In alternative embodiments,the female clasp could be attached to the luggage case 10 and the maleclasp could be attached to the carry strap 15. In addition, in stillfurther embodiments, other attachment means including snaps, buttons,loops, and related attachment means could be used to attach theconvertible carry strap 15 from a shoulder to a backpack strap.

While the invention has been particularly shown and described withreference to a preferred embodiment thereof, it will be understood bythose skilled in the art that various other changes in the form anddetails may be made without departing from the spirit and scope of theinvention.

1. A luggage case 10 comprising: a. a molded, relatively hard-sided rearportion 11; b. a soft-sided front portion 12 attached to said rearportion 11; c. an upper attachment mechanism affixed to said frontportion 12; d. a pair of lower attachment mechanisms affixed to saidrear portion 11; and e. a strap having opposing ends and an intermediateyoke portion, said yoke portion attached to said upper attachmentmechanism and said opposing ends each attached to one of said lowerattachment mechanisms to allow the case to be carried on one's back. 2.The luggage case 10 as defined in claim 1, wherein: a. said yoke portionis elastically extendable.
 3. The luggage case 10 as defined in claim 1,wherein: a. integral to said yoke portion is a connecting means forconnecting said strap to said upper attachment mechanism.
 4. The luggagecase 10 as defined in claim 1, wherein: a. said yoke portion isconstructed of neoprene.